Electrically conductive PTC ink with double switching temperatures and applications thereof in flexible double-switching heaters

ABSTRACT

An article comprising a double-switching heater that comprises a double-switching PTC ink deposited on a flexible substrate to form one or more resistors. The double-switching PTC ink comprises a first resin and a second resin; the first resin provides a first PTC effect within a first temperature range (T1, T2); the second resin provides a second PTC effect within a second temperature range (T3, T4), where T3≥T2; the first resin has an NTC effect above the first temperature range; the second PTC effect is greater than the first PTC effect; and the second PTC effect overlaps with, and is greater than, the NTC effect of the first resin. The substrate can be either thermal polyurethane, nylon or a polyester blend.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 16/454,570, filed Jun. 27, 2019, now allowed, which is adivisional of U.S. patent application Ser. No. 15/441,396, filed Feb.24, 2017, now allowed, which is a continuation-in-part of U.S. patentapplication Ser. No. 15/143,524, filed Apr. 30, 2016, now U.S. Pat. No.10,077,372, which is a continuation-in-part of U.S. patent applicationSer. No. 14/120,638, filed Jun. 12, 2014, and which claims the benefitof U.S. Provisional Application No. 62/389,396, filed Feb. 24, 2016,each of which is hereby incorporated by reference herein in itsentirety.

U.S. patent application Ser. No. 15/441,396, filed Feb. 24, 2017, isalso a continuation-in-part of U.S. patent application Ser. No.14/120,638, filed Jun. 12, 2014, and claims the benefit of U.S.Provisional Application No. 62/389,396, filed Feb. 24, 2016, each ofwhich is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present invention is directed to an electrically conductive ink andrelates to a method of making a PTC screen printable ink with doubleswitching temperatures and applications thereof in flexible,screen-printable polymeric PTC heaters.

SUMMARY OF THE INVENTION

In one aspect, the present invention related to a double-switchingheater comprising a double-switching PTC ink deposited on a substrate toform one or more resistors, the double-switching PTC ink having a firstresin that provides a first PTC effect at a first temperature range anda second resin that provides a second PTC effect at a second temperaturerange, wherein the second temperature range is higher than the firsttemperature range.

In some embodiments, the substrate is a flexible substrate. In someembodiments the substrate is a rigid substrate. In some embodiment, thesubstrate is deformable to generate a three-dimensional structure.

In some embodiments, the substrate is selected from the group consistingof: polyester, polyimide, polyamide, polypropylene, thermoplasticpolyurethane, fiberglass, cement board, carbon composite materials,polyethylene terephthalate, polyethylene, aluminum, steel, glasscomposite, molded plastic, high-density polyethylene and styreneethylene butylene styrene.

In some embodiments, the first resin is selected from the groupconsisting of: polyethylene glycol and polycaprolactone and the firsttemperature range is from 20° C. to 35° C.

In some embodiments, the first resin is selected from the groupconsisting of: polycaprolactone diol and ethylene-vinyl acetatecopolymer and the first temperature range is from 36° C. to 50° C.

In some embodiments, the first resin is selected from the groupconsisting of: low-density polyethylene and maleic acid graftedpolyvinyl chloride and the first temperature range is from 51° C. to 70°C.

In some embodiments, the second resin is selected from the groupconsisting of: polyvinylidene fluoride, poly vinyl chloride,high-density polyethylene, and polyacrylate compounds and the secondtemperature range is from 70° C. to 160° C.

In some embodiments, the heater is encapsulated by an encapsulationmaterial. In some embodiments, the encapsulation material is selectedfrom the group consisting of: polyester, polyimide, polypropylene,rubber, silicone, thermoplastic polyurethane, laminates, ethylene-vinylacetate (EVA) adhesive film, acrylate adhesive film and silicon adhesivefilm, fabric, silicone, and polyethylene terephthalate (PET).

In some embodiments, the heater demonstrates temperature fluctuations of5 degrees at an operating temperature of 48° C.

In some embodiments, the heater demonstrates temperature fluctuations of2 degrees at an operating temperature above 48° C.

In some embodiments, the heater demonstrates substantially nodegradation in relative resistance over multiple operating cycles.

In some embodiments, the heater includes a plurality of resistors inparallel. In some embodiments, the heater includes electricalinterconnects comprising one or more of: metal paste, metal foils,alloys, aluminum, copper, nickel and high-conductivity electronicpolymers.

In some embodiments, the heater includes a sensor positioned proximal tothe heater and a feedback loop to regulate operating temperature.

In another aspect the present invention is directed to a radiant-heatedflooring material comprising a double-switching heater comprising adouble-switching PTC ink deposited on a substrate to form one or moreresistors, the double-switching PTC ink having a first resin thatprovides a first PTC effect at a first temperature range and a secondresin that provides a second PTC effect at a second temperature range,wherein the second temperature range is higher than the firsttemperature range, wherein the double-switching heater is disposedbetween a flooring material and a sub-flooring material.

In another aspect, the present invention is directed to a flooringtextile comprising a double-switching heater comprising adouble-switching PTC ink deposited on a substrate to form one or moreresistors, the double-switching PTC ink having a first resin thatprovides a first PTC effect at a first temperature range and a secondresin that provides a second PTC effect at a second temperature range,wherein the second temperature range is higher than the firsttemperature range, wherein the double-switching heater is bonded to theunderside of the flooring textile.

In another aspect, the present invention is directed to a fluid pipecomprising a double-switching heater comprising a double-switching PTCink deposited on a substrate to form one or more resistors, thedouble-switching PTC ink having a first resin that provides a first PTCeffect at a first temperature range and a second resin that provides asecond PTC effect at a second temperature range, wherein the secondtemperature range is higher than the first temperature range.

In some embodiments, the heater is disposed on the inside of the fluidpipe. In some embodiments, the heater is disposed on the outside of thefluid pipe.

In another aspect, the present invention is directed to a moldcomprising a double-switching heater comprising a double-switching PTCink deposited on a substrate to form one or more resistors, thedouble-switching PTC ink having a first resin that provides a first PTCeffect at a first temperature range and a second resin that provides asecond PTC effect at a second temperature range, wherein the secondtemperature range is higher than the first temperature range, whereinthe heater is disposed on the proximal to a cavity of the mold.

In another aspect, the present invention is directed to an ice cube traycomprising a double-switching heater comprising a double-switching PTCink deposited on a substrate to form one or more resistors, thedouble-switching PTC ink having a first resin that provides a first PTCeffect at a first temperature range and a second resin that provides asecond PTC effect at a second temperature range, wherein the secondtemperature range is higher than the first temperature range.

In another aspect, the present invention is directed to a cookingappliance comprising a double-switching heater comprising adouble-switching PTC ink deposited on a substrate to form one or moreresistors, the double-switching PTC ink having a first resin thatprovides a first PTC effect at a first temperature range and a secondresin that provides a second PTC effect at a second temperature range,wherein the second temperature range is higher than the firsttemperature range.

In another aspect, the present invention is directed to an article ofclothing comprising a double-switching heater comprising adouble-switching PTC ink deposited on a substrate to form one or moreresistors, the double-switching PTC ink having a first resin thatprovides a first PTC effect at a first temperature range and a secondresin that provides a second PTC effect at a second temperature range,wherein the second temperature range is higher than the firsttemperature range.

In another aspect, there is provided a heating composite comprising anencapsulated double-switching heater disposed between a first materialand a second material, wherein the double-switching heater may comprise:a double-switching PTC ink deposited on a substrate to form one or moreresistors, the double-switching PTC ink comprising a first resin and asecond resin, wherein: the first resin can provide a first PTC effectwithin a first temperature range (T₁, T₂); the second resin can providea second PTC effect within a second temperature range (T₃, T₄), whereT₃≥T₂; the first resin has an NTC effect above the first temperaturerange; the second PTC effect is greater than the first PTC effect; andthe second PTC effect overlaps with, and is greater than, the NTC effectof the first resin.

The substrate may be selected from the group consisting of: polyimide,polypropylene, polyethylene terephthalate, polyethylene, polyurethane,glass fiber and silicone.

The first resin can be crystalline or semi-crystalline; and the secondresin can be non-crystalline. The second resin may be selected from thegroup consisting of: polyvinylidene fluoride, polyvinyl chloride,high-density polyethylene, and polyacrylate compounds and the secondtemperature range can be from 70° C. to 160° C.; and/or the first resinmay be selected from: the group consisting of: polyethylene glycol andpolycaprolactone and the first temperature range can be from 20° C. to35° C.; or the group consisting of: polycaprolactone diol andethylene-vinyl acetate copolymer and the first temperature range may befrom 36° C. to 50° C.; or the group consisting of: low-densitypolyethylene and maleic acid grafted polyvinyl chloride and the firsttemperature range may be from 51° C. to 70° C.

Furthermore, the resistance magnification at a switching temperature ofthe heater can be between 15 and 250, while the switching temperature ofthe heater may be between 30° C. and 160° C.

The double-switching heater can be encapsulated in an encapsulationmaterial selected from the group consisting of: polyester, polyimide,polypropylene, rubber, silicone, thermoplastic polyurethane, laminates,ethylene-vinyl acetate (EVA) adhesive film, acrylate adhesive film,polytetrafluoroethylene (PTFE) adhesive film, silicone adhesive film,fabric, silicone, and polyethylene terephthalate (PET).

In addition, the first material can be selected from the groupconsisting of tiles, wood, cement, asphalt, stone, laminate, carpet,vinyl flooring, wallpaper, ceiling tiles, gypsum, plaster, stucco,fiber, metal, roofing tiles and decorative panels. The second materialmay be selected from the group consisting of wood, cement, asphalt,stone, cement board, wall board, gypsum, plaster, ethylene propylenediene monomer (EPDM) rubber, roofing underlayment and ceiling tile.

The encapsulated double-switching heater can be attached to at least oneof the first material and the second material by an adhesive and/or oneor more fasteners.

In addition, a ground plane may be placed between the encapsulateddouble-switching heater and the second material. The ground plane can beattached to an outside surface of the encapsulated double-switchingheater by an adhesive or fastener.

Furthermore, a thermal barrier may be placed between the encapsulateddouble-switching heater and the second material. The thermal barrier maybe inserted in a rigid form or attached to a flexible form of theencapsulated double-switching heater.

In addition, the double-switching heater can comprise a plurality ofresistive elements, and each individual resistive element is regulatedindependently for delivery of heating power.

The encapsulated double-switching heater may be perforated and embeddedin the second material, and the perforated double-switching heater canbe overlaid with a strengthening medium. The strengthening medium can bea fiberglass mat, polyamide mesh, or glass fiber mesh. The strengtheningmedium may be overlaid with a layer of cement that is cured. Inaddition, the substrate may comprise a mat used to strengthen cementboard, and the double-switching PTC ink can be screen printed onto themat.

The encapsulated double-switch heater may be embedded within a polymericmaterial, rubber or silicone. It can be attached to an underside of aflooring textile and may be placed over an underlay of the flooringtextile. The flooring textile may be a carpet or a rug.

The encapsulated double-switching heater may be encapsulated withrubber, fabric, silicone or polyurethane; the first material cancomprise a thermal barrier, and the second material can compriseconcrete, asphalt, sand and/or gravel. The first material may be rubberor a polymer. Furthermore, the encapsulated double-switching heater canbe bonded to a perforated polymeric sheet.

The encapsulated double-switching heater may be encapsulated withrubber, fabric, silicone or polyurethane, with an adhesive attached to afirst surface of the encapsulated double-switching heater; and/or athermal insulation barrier attached to a second surface of thedouble-switching heater.

BACKGROUND

The terms positive temperature coefficient (PTC) materials and, positivetemperature coefficient of resistivity (PTCR) materials, as used herein,refer to materials that increase in electrical resistance when theirtemperature is raised. Polymers can be made electrically conductive bydispersing suitable amounts of conductive particles such as carbon blackor fine metal particles. Polymeric compositions exhibiting positivetemperature coefficient (PTC) behavior and devices incorporating thesame have been used in many applications, especially in electronicindustries, including uses as constant temperature heaters, over currentregulators, and low-power circuit protectors. A typical use in a circuitis limitation of current, which is controlled by the temperature of aPTC element forming part of the circuit.

There are two major ways to produce such PTC compositions, the one ismelt-extruding technology and the other is ink/coating technology. Themelt-extruding technology is most popularly applied but the resultingarticles may be inflexible and are generally unsuitable forconfiguration into the intricate or very thin shapes often desirable foruse on flexible substrates or printed circuit boards. Over recent years,there has been particular interest in the ink/coating technology toproduce polymeric PTC compositions. Reference may be made, for example,to U.S. Pat. Nos. 4,628,187, 5,181,006, 5,344,591, and 5,714,096, andJapanese Patent Publication Nos. 2008293672, 2009151976, and 2009199794.For these inks/coatings, the polymer resins, which are dissolved insuitable solvents, are the binders and the conductive particles aredispersed in the binders to obtain the inks/coatings. Various polymericPTC compositions have been developed, however, most PTC compositionsexhibit Negative Temperature Coefficient (NTC) characteristics ofresistivity immediately after the PTC characteristics. This change fromPTC behaviour to a strong NTC behaviour is often undesirable, and maycause self-burning in some cases. FIG. 1 shows a typical curve of thePTC composition described above. It indicates that when the temperatureT, plotted on a horizontal axis, is in excess of 70° C., the PTC ratioR_(T)/R₂₅ is reduced, PTC ratio being a ratio between a resistance R_(T)at a certain temperature T and a resistance R₂₅ at a temperature of 25°C. The lower resistance leads to excessive current flow and the heatingelement is overpowered. Therefore, the NTC temperature region is apotential safety risk temperature region.

Efforts have been undertaken to reduce or eliminate the NTC effect. Asdisclosed in U.S. Pat. No. 5,227,946 and European Patent EP 0311142,reduction of the NTC effect in polymeric PTC compositions has beenachieved by cross-linking the material. Most effective is post-crosslinking after the forming step either by gamma radiation or acceleratedelectrons. Cross-linking in the melt also erases the NTC effect butnegatively affects the PTC amplitude. In addition, the step ofcross-linking the material increases the time and production costs formanufacturing the PTC composition.

U.S. Pat. No. 8,496,854 discloses a method to reduce the NTC effectwithout cross-linking the material. Their PTC compositions include athermoplastic base resin, an electrically conductive filler andparticles of a polymeric additive dispersed in the PTC composition;wherein the polymeric additive has a melting or softening temperaturegreater than the melting temperature of the thermoplastic resin, whichhelps reduce the NTC effect. The above PTC composition was produced bymelt-extruding technology not like the ink/coating technology used inthe present invention. In addition, the NTC effect is only reduced andnot completely eliminated by the above method.

PTC materials are commonly used in a class of flexible heaterscomprising an electrical resistor that is encapsulated between twopolymer films. The resistor is typically an etched metal foil or,alternatively, an electrically conductive material, or ink, with fixedresistance and suitable properties for printing onto the polymer film.The foil is usually composed of Ni—Cr alloy; the ink is usually composedof an electrically insulating polymer with a dispersed, electricallyconductive powder additive. The conductive powder can be composed ofmetals such as Ag, Au or Sn, electro-conductive ceramics such as WC, orcarbon in various forms such as graphite or carbon black. Carbon is themost common. The powder additive, dispersed three-dimensionallythroughout the polymer, has sufficient volume fraction in the polymer toreach its percolation threshold so as to form a contiguous, conductivenetwork for electrical current to flow throughout the polymer. Bothflexible heater types often have an adhesive on at least one outer sideof the encapsulating film for affixing the heater to the part to beheated.

Polymeric PTC heaters form a subclass of the second type of flexibleheaters described above. These flexible heaters are typicallyencapsulated in a polymer film like other heaters of the type andgenerate heat with an applied voltage, but have printed conductivepolymer elements that can control current, hence control heating power.The temperature at which the electrical resistance starts to increasesharply is referred to as the switch temperature. A “switch temperature”or “switching temperature” as used herein refers to the temperature atwhich the PTC heater generates power only sufficient to maintain thermalequilibrium with its environment, i.e. the point at which the heatertemperature neither rises nor lowers under its own power. Typicalresistance magnification factors range from 5-15 at the switchtemperature. Therefore, they are self-regulating. The switchingmechanism is due to the polymer undergoing a phase change at around theswitch temperature from its normal crystalline molecular structure to anamorphous molecular structure. Because the amorphous material phase hasgreater volume than the crystalline phase, its volume and thermalexpansion interrupts the web of conductors dispersed throughout thepolymer. Upon cooling below the switch temperature, the reversephase-transformation takes place and the conductive network isre-established.

Polymeric PTC flexible heaters are used for a wide variety ofapplications where low temperature, controlled thermal gradients,uniform heating and localized temperature control are crucial, withoutrequiring complex electronic controllers or feedback loops. PTC-basedheater solutions can be found in many aspects of daily life fromautomotive applications (such as external mirror heaters, seat heaters,etc.), to structural home systems (including floor heaters, bed heaters,etc.) to small appliances (like rice or vegetable cookers).

Polymeric PTC flexible heaters are most commonly composed of a polymerwith carbonaceous conductor in the form of carbon black or graphite.This is because polymeric PTC heaters with metal or conductive ceramicsare more expensive and more difficult to deposit as films. However,carbon based polymeric PTC heaters suffer from several importantoperational technical problems.

One such problem is a low resistance magnification at the switchtemperature, typically ranging from 5-15. This results in some powerdissipation even at maximum resistance.

Another problem is the transition temperature region between the lowresistance state and the high resistance state where only partialcurrent flows. The transition region varies in width proportional toambient temperature and the overall conditions for heat transfer.Therefore, the operational characteristics of the heater are determinedby a multitude of design factors involving its physical environment.This affects the heater's power dissipation, the time-to-switch and theheater's hold current.

Another problem is that many PTC heaters exhibit resistance hysteresiswhen switched. This is observed as an increase in resistance from thestarting resistance even hours after the switch event. Over time, theoriginal resistance is approached but it may be days, months or years.Fortunately, the resistance is not cumulative over subsequent switchevents so strategies can be taken to account for it.

Yet another problem is the heater's resistance recovery time after areset event. The time is usually one to two minutes but can be longerdepending on the heat transfer environment of the heater and itsmaterial design.

Still another problem and one that jeopardizes safety of the heaters isa strong NTC effect that most PTC materials exhibit at temperaturesslightly above the temperature at which the strong PTC effect takeshold. The NTC effect causes a dramatic increase in current flowresulting in possible catastrophic failure of the component. This effectis quite problematic for applications of flexible PTC heaters because itcan destroy the heater and even cause a fire.

The present invention provides a method to completely eliminate the NTCeffect of the PTC composition produced by ink/coating technology.

SUMMARY OF THE INVENTION

The present invention provides a PTC ink composition, which is screenprintable and has a high PTC characteristic without any NTC behaviour.The safety risk temperature region in the application of the PTCcomposition has been completely eliminated. There is only one kind ofpolymer as the vehicle in most polymeric PTC compositions. When thetemperature is above the melting point (T_(m)) or softening point(T_(s)) of the polymer, the polymeric PTC composition will turnunstable, which usually results in the NTC behaviour. In the polymericPTC composition of the present invention, two kinds of polymer withdifferent T_(m) or T_(s) are used. The first kind of polymer with alower T_(m) or T_(s) results in the first PTC effect in the workingtemperature region, and the second kind of polymer with higher T_(m) orT_(s) results in the second PTC effect in the safety risk temperatureregion. Therefore, the present PTC composition is also called a PTCscreen printable ink with double switch temperatures.

In another aspect, the present invention describes applications offlexible PTC heaters that utilize the novel composition of PTCconductive ink described above that eliminate the NTC effect, offermagnification factors as high as 250 and switch in the range of 30°-160°C. Applications using this technology therefore are safer, more reliableand dissipate minimal power at switch temperature.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 presents a typical temperature-resistance curve of a typicalprior art PTC composition.

FIG. 2a is a cross sectional view of a flexible double-switching heaterused in a radiant-heating application according to one embodiment of thepresent invention.

FIG. 2b is a circuit according to one embodiment of the presentinvention.

FIG. 3 is a cross sectional view of a flexible double-switching heaterused in a radiant-heating application according to one embodiment of thepresent invention.

FIG. 4 a cross sectional view of a flexible double-switching heater usedin a radiant-heating application according to one embodiment of thepresent invention.

FIG. 5 is a cross sectional view of flexible double-switching heaterused in a snow melting, de-icing and/or anti-icing application accordingto one embodiment of the present invention.

FIG. 6a is a cross sectional view of a flexible double-switching heaterused on the exterior of a water pipe in a point-of use water heatingapplication according to one embodiment of the present invention.

FIG. 6b is a cross sectional view of a flexible double-switching heaterused on the interior of a water pipe in a point-of use water heatingapplication according to one embodiment of the present invention.

FIG. 7 is a cross sectional view of a double-switching heater used in amolding tool application according to an embodiment of the presentinvention.

FIG. 8 presents the temperature-resistance curves of the PTC inkdiscussed in Example 1, Example 2 and Example 3.

FIG. 9 presents the temperature-resistance curves of the PTC inkdiscussed in Example 4.

FIG. 10 presents the temperature profiles of a double-switching PTC filmduring operation.

FIG. 11 presents the temperature profiles of a double-switching PTC filmduring operation.

FIG. 12 presents PTC profile of a double-switching PTC film.

FIG. 13 presents the PTC profile of a double-switching PTC film.

FIG. 14 presents the TCR profile of a double-switching PTC film.

FIG. 15 presents the relative resistance of a double-switching PTC filmplotted relative to a control sample.

FIG. 16 is a cross sectional view of a double-switching heater used in abody warming/pain relief application according to an embodiment of thepresent invention.

FIG. 17 is a cross sectional view of a double-switching heater used in abody warming/pain relief application according to an embodiment of thepresent invention.

FIG. 18 is a plan view of a double-switching heater used in a bodywarming/pain relief application according to an embodiment of thepresent invention.

While the present disclosure is susceptible to various modifications andalternative forms, specific embodiments or implementations have beenshown by way of example in the drawings and will be described in detailherein. It should be understood, however, that the disclosure is notintended to be limited to the particular forms disclosed. Rather, thedisclosure is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of an invention as defined by theappended claims.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides an electrically conductive PTCscreen-printable ink with double switch temperatures and a method ofmaking the same. The electrically conductive PTC ink not only presentsan efficient PTC effect at lower temperatures but also shows a PTCeffect at higher temperatures. When the present PTC ink is applied in aself-regulating heating element with low regulated temperatures (<70°C.), the safety risk temperature region is completely eliminated.

The PTC ink with double switching temperatures is a typicalscreen-printable ink produced by ink/coating technology, whichcomprises:

(1) 10-30 wt % conductive particles;

(2) 5-15 wt % polymer resin 1;

(3) 5-15 wt % polymer resin 2;

(4) 40-80 wt % organic solvent;

(5) 1-5 wt % other additives

The conductive particles can be one or a mixture of more than one ofmetallic powder, metal oxide, carbon black and graphite.

The polymer resin 1 is a crystalline or semi-crystalline polymer, suchas, but not limited to, polyurethane, nylon, and polyester.

The polymer resin 2 is a non-crystalline polymer, such as, but notlimited to, acrylic resin.

The selection of the solvent is based on its boiling point at STP andthe solubility of polymer resins used. The polymer resin 1 and resin 2are completely dissolved in the organic vehicle prior to blending withother components. Any organic, inert liquid may be used as the solventfor the medium (vehicle) so long as the polymer is fully solubilized.

The preferred solvents are selected from Methyl Ethyl Ketone (“MEK”),N-methyl pyrolidone (NMP), toluene, xylene, and the like. The otheradditives include a dispersing/wetting additive and a rheology additive.

Specifically, this invention discloses an ink composition having twodistinct positive temperature coefficient (PTC) characteristics at twodifferent temperature ranges, comprising:

a) 5-15 wt % thermally active polymer resin-1 having a melting point of30-70° C. and providing the first PTC characteristic in the lowertemperature range below 70° C.; preferably being a crystalline polymeror a semi-crystalline polymer.

b) 5-15 wt % thermally active polymer resin-2 having a melting point of70-140° C. and providing the second PTC characteristic in the highertemperature range above 70° C.; preferably being a non-crystallinepolymer

c) 10-30 wt % carbon black.

d) 40-80 wt % organic solvent having a boiling point higher than 100° C.and capable to dissolve both the polymer resin-1 and polymer resin-2.

e) 0-5 wt % additives of enhanced dispersing/wetting and rheologyproperties.

The invented PTC ink is preferably prepared according to the followingsteps. 1) The preparation of 10-30 wt. % polymer solution. For example,80.0 grams of N-methyl pyrolidone is firstly heated to 80° C. and then10.0 grams of polyurethane and 10.0 grams of poly(methyl methacrylate)are added slowly into the system. The mixture is heated at 80° C. for 8hours, yielding a homogenous solution. 2) The preparation of ink base. Adispersing additive 1.0-10.0 wt. % based on the total ink base isfirstly added into the above polymer solution under mechanicallystirring. Then, the carbon black 30-60 wt. % based on the total ink baseis added slowly into the solution under mechanically stirring. Thismixture is then subjected to a three-roll mill to assure properdispersion of the carbon black to form a paste-like ink base. During thethree-roll milling, a rheology additive 1.0-10.0 wt. % based on thetotal ink base may be added to enhance the screen-printing properties ofthe ink base. 3) The preparation of final PTC ink composition. The finalPTC ink can be obtained by mechanically mixing the above polymersolution and ink base at ratios ranging from 0.5/1 to 1/1. The ratiosdepend on the needs of the application design such as the desiredstarting resistance.

The resulting PTC ink is applied to substrates such as polyester films(e.g. DuPont Teijin films) by the screen-printing process. Afterprinting the PTC ink on a polyester film, it is cured in an oven at 120°C. for 10 minutes. In other instances, the film may be cured atdifferent temperatures. Subsequently, a conductive paste, such as DuPont5025 silver paste, suitable for use on polyester substrates is printedover edges of the PTC ink and cured at 120° C. for 5 minutes. The curedPTC film is tested for resistance change with temperature.

Flexible Double-Switching Heaters

In some embodiments, the double-switching PTC ink of the presentinvention may be deposited on a film or other substrate to create aflexible heater comprising the double-switching PTC ink deposited on thefilm (or other substrate). The term “flexible double-switching heater”as used hereinafter refers to a film or other substrate with thedouble-switching PTC ink deposited on the film (or other substrate).Depending on the specific application of a flexible double-switchingheater, different substrates may be used to generate flexibledouble-switching heaters with different thermal stability properties.For example, in some instances, the polyester substrate described abovemay be used to generate a flexible double-switching heater. In otherapplications which require a higher operating temperate (e.g. anoperating temperature around or above 100° C.), a polyimide (e.g. DuPontKapton) or polyamide substrate may be used.

Similarly, various substrates may be used depending on otherapplication-dependent parameters, such as toxicity. For example, incertain applications food-grade substrates such as polypropylene may beused; for clothing, where low weight and flexibility is required,thermoplastic polyurethane (TPU) or fabric itself such as polyesterblend or nylon is appropriate; for high tensile strength applicationssuch as fiberglass reinforced cement board or carbon compositematerials, the strengthening medium, e.g. fiberglass mat, would be used.Other substrates can include but are not limited to: polyethyleneterephthalate (PET), polyethylene (PE), aluminum, steel, glasscomposite, molded plastic, high-density polyethylene (HDPE) and styreneethylene butylene styrene (SEBS).

In some instances, the flexible-double switching heater will have a topfilm positioned over the substrate. Suitable materials for a top filminclude materials suitable for use as a substrate. However, the top filmmay be composed of a different material than the substrate.

Depending on the embodiment, the double-switching PTC ink of the presentinvention may be deposited on the substrate to generate a flexibledouble-switching heater using various techniques. As discussed above,one of the favorable properties of the double-switching PTC ink is thatits dispersion allows for screen printing onto a substrate. In addition,the double-switching PTC ink can be deposited on the substrate usinggravure or rotogravure (e.g. “doctor blade”) techniques. The ink mayalso be dispensed over simple or complex surfaces using nozzles mountedon programmable robots or embedded in components by 3-D printing. Othermethods of depositing PTC ink with substantial accuracy are known in theart.

As discussed above, once the double-switching PTC ink has been depositedon a substrate, silver paste may be deposited on the substrate to createelectrical interconnects (e.g. contacts and bus lines) for use inflexible double-switching heater applications. In some embodiments,other metals (e.g. metal foils or pastes), alloys or electricallyconductive materials such as, but not limited to, aluminum, copper,nickel and alloys thereof, or high conductivity electronic polymers maybe deposited on the substrate to create interconnects. As discussedabove, metal foils, inserted or laminated, may also be used to createelectrical interconnects.

In some applications, the flexible double-switching heater may also beencapsulated with a layer of encapsulation material identical to ordifferent from the substrate used to fabricate the PTC film. Dependingon the embodiment, the flexible double-switching heater may be fully oronly partially encapsulated. Suitable encapsulation materials include,but are not limited to: polyester, polyimide, polypropylene, rubber,silicone, thermoplastic polyurethane, laminates, ethylene-vinyl acetate(EVA) adhesive film, acrylate adhesive film and silicon adhesive film,fabric, silicone, and polyethylene terephthalate (PET).

Additionally, one or both of the layers of encapsulation material mayhave other layers of materials bonded to it such as, but not limited to:materials suitable for use as encapsulation materials, adhesive films,thermal barriers, reflective films, high or low emissivity films,absorptive films, alkaline resistant films, ground planes or EMI/RFIprotective layers.

In various applications, the PTC film may be flexible, semi-rigid and/orrigid. In addition, the PTC film may be deformed (e.g. by heating thePTC film) and shaped into a three-dimensional shape. In variousapplication, the flexible double-switching heater may be positionedproximal to a sensor and may use a feedback loop to adjust itstemperature based on the sensor.

Depending on the embodiment and the type of materials used in making thedouble-switching PTC ink, the flexible double-switching heater may havedifferent PTC effects at different temperate ranges. For example, theswitching temperature of the first PTC effect (i.e. the PTC effect ofthe two PTC effects that has a lower temperature range) can range from30° C.-70° C. Suitable compounds for use as polymer resin-1 to achieve afirst PTC effect at lower temperatures (e.g. from 20° C. to 35° C.)include: polyethylene glycol (PEG) and polycaprolactone. Suitablecompounds for use as polymer resin 1 to achieve a first PTC effect atmid-range temperatures (e.g. from 36° C. to 50° C.) includepolycaprolactone diol and ethylene-vinyl acetate copolymer such as Elvax265 (Du Pont Product). Suitable compounds for use as polymer resin 1 toachieve a PTC effect at high temperatures (e.g. from 51° C. to 70° C.)include low-density polyethylene (LDPE) and maleic acid graftedpolyvinyl chloride (PVC).

Depending on the polymer resin-1 used, a polymer resin-2 may be selectedto provide a second PTC effect that is higher than the first PTC effect,thereby eliminating material degradation due to NTC effect. Suitablecompounds for use as polymer resin-2 include: polyvinylidene fluoride,poly vinyl chloride (PVC), high-density polyethylene (HDPE), and avariety of polyacrylate compounds. The second PTC effect of the secondcompound can range from 70° C. to 160° C.

As discussed below with respect to Example 5, the flexibledouble-switching heaters of the present invention provide variousbeneficial characteristics such as self-regulation of temperature. Asdiscussed with respect to Example 5, the flexible double-switchingheaters of the present invention demonstrate substantial temperatureequilibrium (plus or minus 5° C.) at an operating temperature ofapproximately 48° C. At temperatures greater than 48° C., the flexibledouble-switching heaters demonstrate minor temperature fluctuations(plus or minus 2° C.).

Similarly, as discussed below with respect to Example 6, the flexibledouble-switching heaters of the present invention demonstrate durabilitydue to the second PTC effect. Specifically, the flexibledouble-switching heaters of the present invention demonstrate anegligible reduction in their relative resistance (approximately 1%)over multiple operating cycles with an operating temperature of 65° C.

Radiant Heating Applications.

Flexible double-switching heaters may be used for radiant heated floors,walls and ceilings. FIG. 2a depicts a specific embodiment of a flexibledouble-switching heater 200 used in a radiant-heated floor or ceilingapplication. As discussed above, the flexible double-switching heater200 comprises a PTC film including PTC ink of the present inventionprinted on a substrate. Suitable substrates for radiant-heated floorapplications include: polyethylene terephthalate (PET), polypropylene(PP), polyethylene (PE) and polyimide (PI).

The flexible double-switching heater 200 shown in FIG. 2a isencapsulated in an encapsulation material 230. Suitable encapsulationmaterials for use in this application include: laminates, ethylene-vinylacetate (EVA) adhesive film, acrylate adhesive film and siliconeadhesive film. The encapsulated heater 200 may have an additionalmaterial (not shown) added to the outside of the heater.

As depicted in FIG. 2a , the encapsulated flexible double-switchingheater 200 is inserted between flooring/ceiling materials 220 andsub-flooring/ceiling materials 260. Suitable types of flooring/ceilingmaterials 220 used in this application include, but are not limited to:tiles, hardwood, cement, laminate, carpet, vinyl flooring, wallpaper,ceiling tiles or other decorative material. Suitable types ofsub-flooring/ceiling materials 260 include: flooring underlay, wallboardor ceiling material such as, but not limited to, plywood, cement, cementboard, wall board or ceiling tile. Depending on the embodiment, theencapsulated flexible double-switching heater 200 may be attached to thesub-flooring/ceiling materials 260 and/or the flooring/ceiling materials220 using any kind of attachment material 250. Suitable attachmentmaterials 250 include adhesives (e.g. thinset) and/or mechanicalfasteners.

In various embodiments, a ground plane 240 and/or thermal barrier may beoptionally placed between the encapsulated flexible double-switchingheater 200 and the sub-flooring/ceiling materials 260. For example, aground plane 240 may be required for leakage current monitoring orsafety purposes and/or a thermal barrier 270 may be required for greaterefficiency. In a specific embodiment, the ground plane 240 may belaminated or attached using pressure sensitive adhesive to the outsidesurface of the encapsulated flexible double-switching heater 200. In aspecific embodiment, a thermal barrier 270 may be inserted in rigid formor attached to the encapsulated flexible double-switching heater 200using adhesives or fasteners.

FIG. 2b depicts a printed circuit that regulates temperatureindependently over each small area covered by the individual resistor290. Each resistor in a row is powered by line voltage busses 290 andinterconnects 291. Because the flexible double-switching heater 200material typically has high sheet resistivity, power, P, is determinedby arranging printed resistors in parallel and in rows on the substrateusing the double-switching PTC ink of the present invention. Since powerof a row is P_(row)=V²/R_(row) where V is the applied voltage andR_(row) is the total resistance in the row, the number of resistorsarranged in a row, n, which make up the total resistance in a row by R/ndetermines the total power developed in that row. R is the resistance ofan individual resistor. By making the resistors small (0.2 cm-10 cm) andarranging them in N rows as depicted in FIG. 2b , the power is definedand the temperature at each resistor is independently regulated. Thetotal Power is then written as P=nNV²/R. This circuit pattern allowsindependent temperature control of small areas and temperatureuniformity over the surface of the heater regardless of the localthermal load. The gap between discrete resistors may also be reduced tozero to form a contiguous line of resistor with identical behavior ofthe heater, i.e. local self-regulation in response to local thermal loadconditions.

FIG. 3 depicts another specific embodiment of a radiant-heatedfloor/ceiling application of a flexible double-switching heater 300. Asshown in FIG. 3, the flexible double-switching heater 300 is positionedbetween flooring/ceiling materials 320 and sub-flooring/ceilingmaterials 360. In the specific embodiment depicted, the flexibledouble-switching heater 300 is embedded in the sub-flooring/ceilingmaterials 360. As shown in FIG. 3, the flexible double-switching heater300 is perforated and bonded to a strengthening medium 310 by thesub-flooring/ceiling material 360. The perforations allow thesub-flooring/ceiling material 360 to penetrate the flexibledouble-switching heater 300 in order to anchor the strengthening medium310 to the material 360. In this way, the heater 300, strengtheningmedium 310 and sub-flooring/ceiling material 360 become affixed to eachother.

According to the embodiment, various strengthening mediums 310 may beused including but not limited to: fiberglass mats, polyamide mesh andglass fiber mesh. Suitable sub-flooring/ceiling materials 360 for usedin this embodiment include: cement, cement board, plywood, compositewood products, and composite polymer products. Suitable flooring/ceilingmaterials 320 for use in this embodiment include: tile, laminate,hardwood, carpet, ceiling tile, plaster and/or other standardflooring/ceiling materials as known in the art.

In a specific embodiment, a perforated flexible double-switching heater300 can be embedded in a sub-flooring/ceiling material 360 comprisingcement and overlaid with a strengthening medium 310 comprisingglass-fiber mesh. A layer of cement (not shown) was poured over thestrengthening medium 310 and cured to bond the flexible double-switchingheater 300, the sub-flooring/ceiling material 360 and the strengtheningmedium 310 to each other. In another specific embodiment, the perforatedflexible double-switching heater 300 is embedded in asub-flooring/ceiling material 360 comprising layers of plywood andlaminated.

In another specific embodiment, the perforated flexible double-switchingheater 300 was created using a substrate comprising a mat used tostrengthen cement board (i.e. the double-switching PTC ink was screenprinted onto the mat).

In the embodiment depicted in FIG. 3, the flexible double-switchingheater 300 may be bonded to the underside of the flooring/ceilingmaterial 320 using an attachment material 350 such as those describedabove with respect to FIG. 2.

FIG. 4 depicts another specific embodiment of a flexibledouble-switching heater in a radiant-heated floor/ceiling application.In the embodiment depicted in FIG. 4, the flexible double-switchingheater 400 is encapsulated in an encapsulation material 430. Suitableencapsulation materials 430 include but are not limited to rubber,silicone, polyurethane or other polymers. In some embodiments, theencapsulation material 430 may include its own power supply.

In the specific embodiment depicted in FIG. 4, the encapsulated flexibledouble-switching heater 400 is bonded to the underside of a flooringtextile 490 to form an integral heater. Exemplary flooring textilesinclude, but are not limited to, carpets and rugs. The encapsulatedflexible double-switching heater 400 can be bonded to the flooringtextile 490 using attachment materials 450. Suitable attachmentmaterials for this embodiment include: a variety of adhesive,double-side adhesive tapes or means of physical fixing includinganchoring and stitching.

In the embodiment shown, the encapsulated flexible double-switchingheater 400 that is bonded to the flooring textile 490 is positioned overan underlay 495 for the flooring textile 490. In alternate embodiments(not shown), the encapsulated flexible double-switching heater 400 maybe used as a free-standing floor covering. In other alternateembodiments, the encapsulated flexible double-switching heater 400 maybe used in radiant-heated room application by attaching the encapsulatedflexible double-switching heater 400 to a decorative wall hanging (e.g.a picture) and/or an apparatus (e.g. a space heater) for projectingradiant heat into the room.

Snow Melting, Anti-Icing and De-Icing.

FIG. 5 depicts a flexible double-switching heater used in a snowmelting, de-icing and/or anti-icing application. As shown in FIG. 5, theflexible double-switching heater 500 is encapsulated in an encapsulationmaterial 530. Suitable encapsulation materials 530 for this applicationinclude but are not limited to rubber, fabric, silicone, polyurethane orother tough polymers.

In some embodiments, encapsulated flexible double-switching heater 500may comprise its own power supply (not shown). The encapsulated flexibledouble-switching heater 500 can then be disposed over a sub-surface 540for snow-melting, de-icing and/or anti-icing applications. Exemplarysub-surfaces 540 include, but are not limited to, door steps, walkways,parking areas (e.g. a driveway), road ways (e.g. tarmacs), carports,semi-trailer tops, vehicle structure (e.g. a car or a boat) or buildingcomponents (e.g. a deck, ladder, stair, roof or gutter). Depending onthe embodiment the sub-surface may be comprised of: concrete, asphalt,sand or gravel.

In the embodiment depicted in FIG. 5, the encapsulated flexibledouble-switching heater is disposed above a sub-surface 540 but embeddedbeneath a surface 545. Depending on the embodiment, the surface 545 maybe comprised of: a composite protective layer (e.g. rubber).

In alternate embodiments (not shown), the encapsulated flexibledouble-switching heater 500 can be bonded to a rigid, perforated sheet(e.g. a polymer such as PVC sheet). The sheet comprising theencapsulated flexible double-switching heater 500 can then attached to asurface 540 for example by embedding the sheet in the surface and/orunderlaying the surface with the sheet.

In another alternate embodiment, the encapsulated flexibledouble-switching heater 500 can comprise an adhesive layer (not shown)on one of its surfaces. Similarly, the encapsulated flexibledouble-switching heater 500 may comprise a thermal insulation barrier(not shown) on one of its surfaces. In a specific embodiment, theencapsulated flexible double-switching heater 500 may have an adhesivelayer (not shown) on one surface and a thermal insulation barrier (notshown) on the opposite surface. In yet another embodiment, a flexibledouble-switching heater as described above with adhesive layer on oneside and thermal insulation barrier on the opposite side is wrapped onto a water pipe, valve or fitting to prevent freezing,

Water-Heating and Other Fluid Applications

FIGS. 6a and 6b depict flexible double-switching heaters for use inpoint-of-use, on-demand and tank form applications. FIG. 6a shows asimple point-of-use water pipe 680 which is wrapped in a flexibledouble-switching heater 600. The embodiment depicted in FIG. 6 a may beused, for example, in a portion of water pipe 680 that is proximal to afaucet, shower head or other dispensing mechanism (not shown).

FIG. 6b shows an alternate embodiment of a water pipe or cavity 681 thathas multiple plates comprising flexible double-switching heaters 601,602, 603 mounted inside the water pipe 681 in a portion of the waterpipe 681 that is proximal to a faucet, shower head or other dispensingmechanism (now shown).

Plastics and Metal Molding.

FIG. 7 depicts an application of a flexible double-switching heater in aplastics, rubber, silicone, composite material and metal moldingapplication. Heating molds during part or all of the molding cycle canpromote efficient filling of mold cavities, reduced tonnage of injectionmolding equipment, controlled cooling during solidification of the part,superior optical properties, elimination of autoclaves and ovens andsimplification of heating equipment and controls. When applied to theoutside surface of very large molds, as for kayaks; or for compositematerials molding, as for aircraft or automotive components; or rubbermolds, as for automobile tires; or for rotational molds as for plasticstorage tubs; flexible double-switching heaters increase productivity byeliminating batch oven processing, allow selective application of heatand in some cases eliminate the use of steam. Other applications arebarrels, hot runners, nozzles, mold cavities, sprues and transfer potsfor transfer molding; preheaters and mold cavity heaters for compressionmolding; and extruders and molds for blow molding. Yet otherapplications are for dies in the casting of metals and the extrusionmolding of polymers for components such as films and pipes.

In the embodiment depicted in FIG. 7, a mold 770 comprising a heated hotrunner and nozzle 790 has a flexible double-switching heater 700disposed on the outside of the mold cavity 770. Depending on theembodiment, the mold 770 may be a large mold 700, e.g. 1.5 meters indiameter and 1.5 meters high, or a small mold 770, e.g 2 cm.×2 cm. Inaddition, in alternate embodiments (not shown), the flexibledouble-switching heater 700 may be disposed on the inside of the mold700 provided it is fitted with a suitable overlaying material such asmetal foil that is compatible with the physical conditions oftemperature, pressure and reaction with the melt.

Residential, Commercial and Cooking Appliances.

Other exemplary applications of flexible double-switching heaterinclude, but not limited to, warming drawers, slow cookers, coffeemakers, hot potable water supplies, electric teapots, ice cube trays andsteam generators. Other residential applications are bathtubs,refrigerator defrosters, dishwasher vents, towel warmers, toilet seatwarmers and dry sauna heaters. As discussed above, depending on theembodiment and the type of materials used in making the flexibledouble-switching heater, the switching temperature of the first PTCeffect can range from 30°−70° C.

Suitable substrates for this application include: polyethyleneterephthalate (PET) and polyimide. Depending on the embodiment, theflexible double-switching heaters may be encapsulated withethylene-vinyl acetate (EVA) and/or acrylics.

Automotive Heating

Flexible double-sided heaters may also be used for automotiveapplications such as, but not limited to, seat warmers, electric carbattery warmers, mirror warmers, steering wheel warmers, and coldweather accessories such as heaters for fuel piping, oil pans,transmission pans, batteries and engine blocks. Suitable substrates forthis application include: aluminum, steel, carbon or glass composite,molded plastic, high-density polyethylene (HDPE) and styrene ethylenebutylene styrene (SEBS). Depending on the embodiment, the flexibledouble-switching heaters may be encapsulated with standard polymers suchas polyethylene terephthalate (PET), ethylene-vinyl acetate (EVA),acrylics and silicon.

The advantage of using PTC heaters is the elimination of a temperaturesensor, elimination of controller or power supply, excellent temperatureuniformity and efficiency. The latter advantage arises from the PTC inkbeing formulated to switch at a desired level.

EXAMPLES

The invention will now be described in more detail with reference to thefollowing examples. However, it should be understood that these examplesare given for the purpose of illustration only and are not intended tolimit the scope of the present invention.

Compositions for the Examples below are summarized in TABLE 1, where allcomponent concentrations are expressed as percentage by weight based onthe total ink composition.

TABLE 1 Polymer Polymer Carbon Dispersing Rheology Resin 1 Resin 2 blackSolvent additive additive Examples (wt. %) (wt. %) (wt. %) (wt. %) (wt.%) (wt. %) Example 8.0 8.0 23.0 56.0 2.00 3.00 1 Example 10.0 10.0 21.055.0 1.50 2.50 2 Example 12.0 12.0 19.0 54.0 1.00 2.00 3

Example 1

The PTC ink and film were made following the typical procedure describedabove. The polymer resin-1, polymer resin-2, carbon black, solvent,dispersing additive, and rheology additive used in this Example, Example2 and Example 3 are respectively polyethylene glycols (Carbowax 1450from Dow Chemicals) with a melting point ranging from 42−46° C.,polyvinylidene fluoride (PVDF) (Solef460 from Solvay) with a meltingpoint of 155-160° C., carbon black REGAL 350R, NMP, BYK-220S, andBYK-410, and their contents in the PTC compositions are listed inTABLE-1.

In order to test the PTC ink for dispersion and resistivity, the PTC inkcompositions of Examples 1, 2 and 3 were screen-printed onto polyesterfilm to produce four strips, each strip having dimensions ofapproximately 1 cm by 10 cm. Silver contacts were applied to both endsof each strip in order to measure resistance and experimental error. Inaddition, a 5 cm by 5 cm square was printed to evaluate dispersion anduniformity. The composition of Example 1 yielded resistivity at 25° C.of the PTC film from this example is 3.9 Kohm/sq. FIG. 8 show thetemperature-resistance curves of it.

Example 2

The conditions were used as Example 1, but more polymer solution wasadded into the system. The resistivity at 25° C. of the PTC film fromthis example is 8.0 Kohm/sq. FIG. 8 shows the temperature-resistancecurves generated using this Example.

Example 3

The same conditions were used as Examples 1 and 2, but more polymersolution was added into the system. The resistivity at 25° C. of the PTCfilm from this example is 15.0 Kohm/sq. FIG. 8 shows thetemperature-resistance curves generated using this Example.

As shown in FIG. 8, the PTC ink of the present invention presents goodPTC effect, at 60° C., the PTC ratio RT/R-25 is higher than 10, thevalue of sample 3 is even higher than 20. As the temperature is raisedfurther, no NTC effect appear, it still present good PTC effect, at 120°C., the PTC ratio RT/R-25 is higher than 30, the value of sample 3 iseven higher than 50. When the present PTC ink is applied in aself-regulating heating element with low regulated temperatures (<70°C.), the safety risks area is completely eliminated.

Example 4

The PTC ink and film were made following the procedure as described inExample 1. Commercially available polymer Elvax 265 (from DuPont) havinga softening point of 49° C. was used as the first thermally activepolymer resin-1. Another commercially available polymer BR-106 (BR-106,DIANAL resins purchased from Univar Canada Ltd) having a melting pointof above 160° C. was used as the thermally active polymer resin-2.Commercially available carbon black Monarch 120 (from Cabot) was used asconductive particle. Commercially available solvent TEP (TriethylPhosphate from Eastman) having a boiling point of about 209° C. was usedas the solvent. BYK-220S, and BYK-410 were used as dispersing additiveand rheology additive respectively. The content by weight of eachcomponent in the PTC compositions are listed in TABLE-2. The measuredsheet resistivity of the PTC film generated using the PTC ink of thisexample screen printed onto a polyester substrate is 8.0 KΩ/⋄ at 25° C.,and exhibits the temperature coefficient ratio (TCR) profile illustratedin FIG. 9. The TCR is the ratio between the resistance at a giventemperature and the resistance at room temperature (27° C.).

TABLE 2 Polymer Polymer Carbon Dispersing Rheology Resin 1 Resin 2 blackSolvent additive additive Examples (wt. %) (wt. %) (wt. %) (wt. %) (wt.%) (wt. %) Example 8.0 18.0 18.0 52.0 2.00 2.00 4

Example 5

To further test the PTC film of the present invention, thedouble-switching PTC ink of Example 4 was printed onto a 500 mm by 500mm square of polyester film to form 64 (in a configuration of 14×6) PTCheating strips in parallel connection by silver bus lines generatedusing silver paste (DuPont 5025). Each strip was 2 cm by 4 cm and thestrips were placed at intervals of 1 cm. After sequentiallyprinting/drying of PTC ink (Example 4) and silver paste (DuPont 5025),the heating element was laminated with a standard EVA/PET film withcopper ribbons embedded on both sides as the electrodes and yielded anoverall effective initial resistance of 1.4KΩ at 27° C. 220 V/60 Hz ofpower was supplied to the electrical electrodes and generated an initialheating power of 34.6 watt, which was equal to a power density of 138.4watt/m2 at 27° C.

Nine temperature probes where placed across the heating element atdifferent positions to check the temperature uniformity. To check theself-regulating properties of the double-switching PTC ink, the heatingelement was placed under a thick blanket to reduce the heat loss to thesurrounding environment. FIG. 10 demonstrates the temperature profilesobserved over the first ten minutes of operation for each probe. FIG. 11demonstrates the temperature profiles observed over the first 150minutes of operation. As shown in FIGS. 10 and 11, there is somevariance in temperature profiles due to the probe's position variationand heat loss associated therewith, i.e., the heat loss was more at theouter edges than at the center. However, both Figures demonstrate thatthe all of the temperature profiles reach an equilibrium afterapproximately 60 minutes.

In addition, the resistance of the various strips was measured withvarying voltages to produce the PTC profiles shown in FIGS. 12 and 13.FIG. 14 includes the Temperature Co-efficiency Ratio (TCR) measured overvarying temperatures. The TCR is the ratio between the resistance at agiven temperature and the resistance at room temperature (27° C.).

Example 6

To examine the durability of a flexible double-switching heater madeusing a double-switching PTC ink of the present invention, a flexibledouble-switching heater was made by printing the double-switching PTCink of Example 4 onto a polyester substrate. Electrical components weremade by disposing silver paste (DuPont 5025) onto the substrate afterthe ink was cured. A reference sample was generated using the sametechnique but substituting a commercially available PTC ink (DuPont7282) for the ink of the present invention.

To measure resistance strips of 1×10 cm dimensions of both thedouble-switching PTC ink and the reference PTC ink were printed onto thesubstrate and subject to 25 operating cycles. During each operationcycle, the strips were heated to 65° C. at a relative humidity of 60%for 24 hours then allowed to cool to room temperature (27° C. at arelative humidity of 40%) for 24 hours. Resistance was measured at theend of each operating cycle (i.e. following the 24-hour period at roomtemperature). For the experimental and reference sample, the relativeresistance of each sample was calculated by dividing the resistanceobtained at each operating cycle by the initial measured resistance.

FIG. 15 shows the relative resistance for both samples measured over the25 operating cycles. As shown in FIG. 15, the relative resistance of thedouble-switching PTC ink of the present invention suffers only slightdegradation due to the elimination of NTC effect obtained by the secondPTC effect. Conversely, the reference sample with conventional PTC inkhad diminished relative resistance over time, suggesting an NTC effecthad caused material degradation.

Further Applications: Body Warming/Pain Relief

A flexible double-switching heater comprising a double-switching PTC inkdeposited on a flexible substrate may also be used as an article forbody warming and/or pain relief applications such as, but not limitedto, heating pads, heat wraps, heated blankets, heated throws, heatedbody pillows and heated mattress pads. The double-switching PTC ink hasa first resin that provides a first PTC effect at a first temperaturerange and a second resin that provides a second PTC effect at a secondtemperature range, wherein the second temperature range is higher thanthe first temperature range. In some embodiments, the first temperaturerange is between 30 C-70 C. Suitable substrates for this application arelow-weight and flexible, and can include for example, thermoplasticpolyurethane (TPU) or fabric itself such as polyester blend or nylon.

The advantage of using PTC heaters is the elimination of a temperaturesensor, elimination of controller or power supply, elimination ofphysical connectors (e.g. wires), excellent temperature uniformity andefficiency. The latter advantage arises from the PTC ink beingformulated to switch at a desired level, as well as the layout/design ofthe article. In addition, the article can achieve heating temperatureswith lower voltage. In addition, the article can be laundered.

In some embodiments, the double-switching PTC ink 1600 is deposited ontoa TPU substrate 1610 using a method of screen printing, as shown in FIG.16. In some embodiments, the double-switching PTC ink/TPU substrateassembly (i.e. the double-switching flexible heater) is cured usingheat, and then encapsulated in an encapsulation material 1700, as shownin FIG. 17. Suitable encapsulation materials for use in this applicationinclude a dielectric ink or other thin film. In some embodiments, theencapsulated heater is inserted, sewn or otherwise attached to a fabricor shell (that is placed adjacent to a user) to form the article forbody warming and/or pain relief.

FIG. 18 is a plan view of a double-switching heater used in a bodywarming/pain relief application according to an embodiment of thepresent invention. FIG. 18 illustrates a thin film panel 1800 comprisinga double-switching PTC ink 1810 screen printed onto a TPU substrate1815, cured with heat, and encapsulated with a dielectric ink (notshown). Panel 1800 also comprises a series of printed conductive traces1820 that are screen printed onto the TPU, cured, and laminated with adielectric ink. The conductive traces 1820 are designed to carry theelectrical current. In FIG. 18, the conductive traces 1820 runperpendicular through the printed double-switching PTC ink, whichcreates a plurality of individual resistors 1810 that generate heat.Each individual resistor is also self-regulating due to the propertiesof the double-switching PTC ink properties, which relates to the abilityof each individual resistor resisting the electrical current enough toprevent overheating, fires and failures. In some embodiments, printedsilver traces are used.

In one example of body warming/pain relief application, adouble-switching PTC ink was deposited onto a TPU substrate using amethod of screen printing. A voltage of 120VAC was applied to thearticle, resulting in a watt density of between 5-10 watts/ft², oraround 7 watts/ft². While the article can be any shape, in this example,it was square or rectangular. The square measured from 6 in×6 in to 24in×24 in, or about 12 in×12 in. The rectangle measured from 6 in×12 into 18 in×30 in, or about 12 in×24 in. The self-regulating temperature ofthe double-switching ink was about 60 C, while the temperature of thearticle where applied to a user was about 50 C to about 55 C or about 52C. In general, an article can be designed to obtain a range ofself-regulating temperatures and watt densities, in order to achievespecific metrics required by a customer.

In a second example of body warming/pain relief application, adouble-switching PTC ink is deposited onto a TPU substrate using amethod of screen printing. A voltage of about 11.1 VDC was applied tothe article, resulting in a watt density of between 60-70 watts/ft², orabout 65 watts/ft². While the article can be any shape, in this example,it was square, measuring from 6 in×6 in to 24 in×24 in, or about 12in×12 in. The self-regulating temperature of the double-switching PTCink was about 73 C, while the temperature of the article where appliedto a user was about 60 C to about 70 C or about 65 C. In general, anarticle can be designed to obtain a range of self-regulatingtemperatures and watt densities, in order to achieve specific metricsrequired by a customer.

While particular implementations and applications of the presentdisclosure have been illustrated and described, it is to be understoodthat the present disclosure is not limited to the precise constructionand compositions disclosed herein and that various modifications,changes, and variations can be apparent from the foregoing descriptionswithout departing from the spirit and scope of an invention as definedin the appended claims.

The invention claimed is:
 1. An article comprising a double-switchingheater, the double-switching heater comprising: a double-switching PTCink deposited on a flexible substrate to form one or more resistors, thedouble-switching PTC ink comprising a first resin and a second resin,wherein: the substrate is either thermal polyurethane, nylon or apolyester blend; the first resin provides a first PTC effect within afirst temperature range (T1, T2); the second resin provides a second PTCeffect within a second temperature range (T3, T4), where T3≥T2; thefirst resin has an NTC effect above the first temperature range; thesecond PTC effect is greater than the first PTC effect; and the secondPTC effect overlaps with, and is greater than, the NTC effect of thefirst resin.
 2. The article of claim 1, wherein the substrate is thermalpolyurethane.
 3. The article of claim 1, wherein the double-switchingPTC ink is screen printed onto the substrate.
 4. The article of claim 1,wherein the double-switching heater is encapsulated by a dielectric inkor a thin film.
 5. The article of claim 4, wherein the double-switchingheater is encapsulated by a dielectric ink.
 6. The article of claim 1,wherein the double-switching heater further comprises a plurality ofconductive traces.
 7. The article of claim 6, wherein the plurality ofconductive traces are laminated with a dielectric ink.
 8. The article ofclaim 6, wherein the plurality of conductive traces are each silvertraces.
 9. The article of claim 1, wherein: the first resin iscrystalline or semi-crystalline; and the second resin isnon-crystalline.
 10. The article of claim 1, wherein a switchingtemperature of the double-switching heater is between 30° C. and 160° C.11. The article of claim 1, wherein: the second resin is selected fromthe group consisting of: polyvinylidene fluoride, polyvinyl chloride,high-density polyethylene, and polyacrylate compounds and the secondtemperature range is from 70° C. to 160° C.; and/or the first resin isselected from: the group consisting of: polyethylene glycol andpolycaprolactone and the first temperature range is from 20° C. to 35°C.; or the group consisting of: polycaprolactone diol and ethylene-vinylacetate copolymer and the first temperature range is from 36° C. to 50°C.; or the group consisting of: low-density polyethylene and maleic acidgrafted polyvinyl chloride and the first temperature range is from 51°C. to 70° C.
 12. The article of claim 1, wherein the article is aheating pad, a heat wrap, a heated blanket, a heated throw, a heatedbody pillow or a heated mattress pad.
 13. A panel comprising anencapsulated double-switching heater, the double-switching heatercomprising a double-switching PTC ink deposited on a flexible substrateto form one or more resistors, the double-switching PTC ink comprising afirst resin and a second resin, wherein: the substrate is thermalpolyurethane; the first resin provides a first PTC effect within a firsttemperature range (T1, T2); the second resin provides a second PTCeffect within a second temperature range (T3, T4), where T3≥T2; thefirst resin has an NTC effect above the first temperature range; thesecond PTC effect is greater than the first PTC effect; the second PTCeffect overlaps with, and is greater than, the NTC effect of the firstresin; and the double-switching heater is encapsulated in a dielectricink.
 14. The panel of claim 13, wherein the double-switching PTC ink isscreen printed onto the substrate.
 15. The panel of claim 13, whereinthe encapsulated double-switching heater further comprises a pluralityof conductive traces.
 16. The panel of claim 15, wherein the pluralityof conductive traces are laminated with a dielectric ink.
 17. The panelof claim 15, wherein the plurality of conductive traces are each silvertraces.
 18. The panel of claim 13, wherein: the first resin iscrystalline or semi-crystalline; and the second resin isnon-crystalline.
 19. The panel of claim 13, wherein a switchingtemperature of the double-switching heater is between 30° C. and 160° C.20. The panel of claim 13, wherein: the second resin is selected fromthe group consisting of: polyvinylidene fluoride, polyvinyl chloride,high-density polyethylene, and polyacrylate compounds and the secondtemperature range is from 70° C. to 160° C.; and/or the first resin isselected from: the group consisting of: polyethylene glycol andpolycaprolactone and the first temperature range is from 20° C. to 35°C.; or the group consisting of: polycaprolactone diol and ethylene-vinylacetate copolymer and the first temperature range is from 36° C. to 50°C.; or the group consisting of: low-density polyethylene and maleic acidgrafted polyvinyl chloride and the first temperature range is from 51°C. to 70° C.